Method and apparatus for cutting one or more grooves in a cylindrical element

ABSTRACT

Embodiments of the subject invention relate to a method and apparatus for cutting one or more grooves in a cylindrical element. In specific embodiments, the one or more grooves are cut into an outer surface of the cylindrical element. The cylindrical element can be solid, or can have one or more hollow portions. In a specific embodiment, the cylindrical element is a hollow tube. Embodiments also pertain to a cylindrical element having one or more grooves cut in an outer surface of the cylindrical element. Further specific embodiments are directed to cylindrical elements having one or more grooves that can be utilized as a drapery or curtain tube, where the one or more grooves, in combination with rotation of the cylindrical element, can be used for moving the drapery to one or more positions along the tube, such as from an open position for the drapery or curtain to a closed position for the drapery or curtain, by engaging an interconnecting element between the drapery or curtain and the one or more grooves while rotating the tube.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims the benefit of U.S. ProvisionalApplication Ser. No. 61/702,093, filed Sep. 17, 2012, which is herebyincorporated by reference herein in its entirety, including any figures,tables, or drawings.

BACKGROUND OF INVENTION

Embodiments of the invention relate to cutting one or more grooves in acylindrical element.

U.S. Pat. No. 4,125,057 (Cox) teaches a motor driven milling and boringmachine used primarily for forming screw threads of any selected pitch,external to cylindrical or conic projection or within similar-shapedbore of workpiece, particularly workpieces such as are too large orirregular-shaped to be themselves rotated. A tubular housing, upstandingor tiltably disposable, journals a longitudinally displaceable androtatable hanger which in turn axially journals a power-driven spindlehaving a selectively offset-positionable stub portion, terminallycarrying a thus radially extensible drive segment which distallypositions a rotary milling cutter. A second or planetary tracking motorjointly operates a pair of selectively coupled ring gears of thehousing, which in conjunction with a master nut fixed along the housingaxis, move the hanger respectively annularly and axially so that thedistal cutter may follow a helical path, the pitch of which path isdetermined by the chosen velocity ratio give the two ring gears. Aparticular velocity ratio results from the choice of gearing assembledin a detachable twin-segment gear train cassette insertable between thepair of ring gears. While remaining in place, the gear train may bedisengaged from one drive component of the hanger to enable arcuateresetting for production of multi-start threads, or alternately toprovide annular or linear movement of the cutter. A collar-shapedelectromagnetic support base has associated tactile means for centeringit, and hence centering the milling machine subsequently mountedthereupon, relative to the preformed bore of a workpiece which is to bethreaded. Radial thrust-retraction means are provided forquick-withdrawal of a cutter head from a workface so that it can then belifted out of a bore without retracing the helical entrance path.

U.S. Pat. No. 4,212,568 (Minicozzi) teaches a rotary cutting tool blankcomprising a cutting portion having a longitudinal axis and a pluralityof teeth extending the length of said cutting portion, with each of theteeth having a cutting face and a trailing face and a land surfacebridging the cutting and trailing faces. The land surfaces areinterrupted by a plurality of spaced transverse depressions ofrelatively large radius arcuate cross section to form a plurality ofcutting edge portions at the junction of the cutting face and theuninterrupted portions of the land surface. The cutting edge portionshave a positive rake angle, and the trailing and cutting faces of eachtooth have surfaces which undulate generally sinusoidally from one endof the cutting portion to the other so that the rake angle of eachcutting edge portion varies continuously along its length. The cuttingtool blank can be transformed to a cutting tool ready for use simply bysuitably relieving the land surfaces to form cutting edges at theaforementioned cutting edge portions.

U.S. Pat. No. 4,996,861 (Kellum) teaches an apparatus including anexternally threaded spindle to which one end of a thin walled metal tubeis detachably secured. The spindle is rotated to wind the tube into theexternal thread, thereby producing a helix. As the tube is wound ontothe spindle, it is pressed into the thread grooves by an auxiliaryroller.

U.S. Pat. No. 5,263,381 (Shirai) teaches a ball screw comprising athreaded rod and a ball nut making a rectilinear motion around the rodas the rod is rotated. A first load ball groove and a second load groovewhich have an offset relation to each other are formed in the innersurface of the ball nut. A pre-load is imparted to ball bearings rollingin these two load grooves. The ball nut has a resilient portion betweenthe first and second load ball grooves. The resilient portion can bedisplaced axially. Any excessive pre-load created by the errorintroduced either in the lead of the ball-rolling groove or in the leadof the first or second load ball groove is absorbed by the resilientportion. Consequently, the novel ball screw is superior in accuracy tothe prior art ball screw, and is easier to fabricate.

U.S. Pat. No. 5,775,187 (Nikolai et al) teaches a method of machiningand a tool is used for obtaining patterns in the form of alternatingridges, pads, cells, and ridges of a triangular cross section on thesurface of a blank. The method facilitates selection of the geometricalparameters of the tool and the machining mode for the tool to obtainalternating ridges and depressions with parallel sides of the profile atpredetermined intervals and predetermined heights and angles of slope.The width of the space between projections can be varied in the range ofmillimeters and micrometers.

U.S. Pat. No. 5,971,045 (Watanabe) teaches a veneer lathe comprising aknife (2) for peeling a log (1), which is secured rotatably to a knifestock, and a roller bar (3) disposed to press a circumferential surfaceof the log (1) at an upstream side, in relative to said knife (2), of arotational direction of the log (1). The roller bar (3) has a diameterof not more than 30 mm, and is provided on the circumferential surfacethereof with a large number of projections (5) whose height is nothigher than the circumferential surface of the roller bar (3). Theroller bar (3) is sustained in a sliding bearing (9) and adapted toreceive a rotational force from a driving source. The roller bar (3)functions not only as a pressure bar but also as a power transmittingmedia to rotate the log (1), thereby preventing the generation of lathecheck of veneer to be produced.

U.S. Pat. No. 6,186,756 (Kojima) teaches a rotor 1 forming screw teethprojectingly provided at its outer end 2 on the axis thereof with acenter shaft 3. The center shaft 3 is provided at its outer end 4 with asmaller-diameter shaft 5 or a concaved fitting hole. A separate rotorshaft 6 which is to be fitted over the smaller-diameter shaft 5 orfitted into the concaved fitting hole is provided with another concavedfitting hole 7 or smaller-diameter shaft. A metal shaft around whichsynthetic resin is molded is formed at its peripheral surface with aspiral groove or corrugated groove in the opposite revolutionaldirection with respect to the revolutional direction of the screw rotor.The spiral groove is formed with smooth arc curved line connectingprofiles of adjacent grooves. The shaft is provided with a step, andsynthetic resin is molded around the shaft surface to form a screwrotor.

U.S. Pat. No. 6,289,595 (Galestien) teaches the determination of thecomplete two-dimensional axial cross section of internal and externalscrew threads and similar workpieces, wherein in a plane through thecenterline of the workpiece, two screw thread profiles which are locateddiametrically opposite each other are measured through twotwo-dimensional scan measurements in this plane or through arithmeticconstruction based on two profile depth measurements with a measuringball or measuring wire, further on the basis of the assumption that thescrew thread profiles in question further have a known dimension andgeometry, whereafter these two opposite profiles are linked to eachother by performing one or more linked measurements such as, forinstance, the outside diameter in the case of external screw thread andthe core diameter in the case of internal screw thread. If a properconcentricity of the core diameter, the outside diameter and flankdiameter is involved, it may suffice to measure or scan only one profileand one or more linked measurements.

U.S. Pat. No. 7,849,769 (Akiyama) teaches a precision roll turning lathewhich can form a pattern including three-dimensionally shaped portions,such as three-sided pyramids, on the surface of a roll, with highaccuracy. Specifically, a tool post is provided with a tool turning axis(A axis) which is used to turn a tool such that, when forming a spiralgroove cut through the roll, a cutting face of a tip of the tool isoriented perpendicular to a direction along which the spiral grooveextends.

U.S. Pat. No. 8,308,463 (Kataoka) teaches providing a screw rotorincluding a resin rotor formed around a metallic shaft withoutgeneration of cracks. Spiral chamfers are formed on surfaces of metallicshafts around which resin rotors are formed. Preferably the surfaces ofthe shafts may be sandblasted, and after the surfaces of the shafts arepreliminarily coated with resin and then the rotors may be molded.

The prior art teaches several methods to form helical or spiralinggrooves in or on the outer surface of a shaft or tube. Some of thesemethods are complicated and time consuming ways of forming or machiningthe grooves. Accordingly, there is a need for a method and apparatus formore efficiently and/or more accurately machining grooves in an outersurface of a cylindrical shaft or tube.

BRIEF SUMMARY

Embodiments of the subject invention relate to a method and apparatusfor cutting one or more grooves in a cylindrical element. In specificembodiments, the one or more grooves are cut into an outer surface ofthe cylindrical element. The cylindrical element can be solid, or canhave one or more hollow portions. In a specific embodiment, thecylindrical element is a hollow tube. Embodiments also pertain to acylindrical element having one or more grooves cut in an outer surfaceof the cylindrical element. Further specific embodiments are directed tocylindrical elements having one or more grooves that can be utilized asa drapery or curtain tube, where the one or more grooves, in combinationwith rotation of the cylindrical element, can be used for moving thedrapery to one or more positions along the tube, such as from an openposition for the drapery or curtain to a closed position for the draperyor curtain, by engaging an interconnecting element between the draperyor curtain and the one or more grooves while rotating the tube.

A specific embodiment involves machining two grooves, 180 degrees apart,around the outer surface of a cylindrical shaft or tube with a righthand, or clockwise, twist, and/or two grooves, 180 degrees apart, aroundthe outer surface of the cylindrical shaft or tube with a left hand, orcounter clockwise, twist.

Specific embodiments of the subject method and apparatus can incorporateone or more of the following features: machining multiple singledirection (right hand or left hand) grooves in the shaft or rod at thesame time; machining two grooves using two single point tools spaced adistance ½ the length of the lead; machining a groove using multiplesingle point tools where each single point tool machines a portion ofthe groove, such as a single point tool machining a rough cut depth anda further single point tool machining a finish cut depth; machiningmultiple right hand, or clockwise, grooves in one pass along the shaftor tube and, optionally, machining multiple left hand, or counterclockwise, grooves using an opposite directional single pass along theshaft or tube, where if more than one single point tool is used for eachgroove, the positions of the rough cut depth tools and the finish cutdepth tools are reversed between the pass and the opposite directionalpass; machining two grooves in each direction within two minutes for aten foot shaft or tube; minimum set up time; machining either multiplegrooves in a single direction or multiple groove in two directions;machining a groove using two or more tools in a single pass, whichreduces tool changes compared with making a separate pass for each tool;and machining two or more grooves in a single pass using different toolsfor each groove, such that the alignments of the grooves are moreaccurate compared with machining each of the two or more grooves inseparate passes.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of an apparatus for cutting one or moregrooves in a cylindrical element, where the apparatus is cutting aunidirectional set of grooves.

FIG. 2 is an enlarged perspective view of the embodiment shown in FIG.1.

FIG. 3 is an enlarged top view of the embodiment shown in FIG. 1,showing the tool holder, with a portion of a cylindrical tube shown witha cutaway in order to show the placement of the tools.

FIG. 4 is a perspective view of the apparatus of FIG. 1, where theapparatus is cutting bidirectional sets of grooves.

FIG. 5 is an enlarged perspective view of the embodiment shown in FIG.4.

FIG. 6 is an enlarged top view of the tool holder, with a portion of acylindrical tube shown with a cutaway in order to show the placement ofthe tools.

FIG. 7 shows a unidirectional pair of grooves cut in a cylindrical tubein accordance with an embodiment of the subject invention.

FIG. 8 is an enlarged end view of the cylindrical tube of FIG. 7.

FIG. 9 shows two bidirectional pairs of grooves cut in a cylindricaltube in accordance with an embodiment of the subject invention.

FIG. 10 is an enlarged end view of the cylindrical tube of FIG. 9.

FIG. 11A shows an embodiment of a prior art bit or tool.

FIG. 11B shows an embodiment of a bit or tool in accordance with aspecific embodiment of the subject invention.

FIG. 11C shows an embodiment of a bit or tool in accordance with aspecific embodiment of the subject invention.

FIGS. 12A, 12B, and 12C show an embodiment of a tool holder thatincorporates two rows of tools.

DETAILED DISCLOSURE

Embodiments of the subject invention relate to a method and apparatusfor machining one or more grooves on an outer surface of a cylindricalelement. The terms rod or shaft can refer to a solid cylindrical objectthat may be made of a single material or multiple materials, and may behomogeneous or may be inhomogeneous, such as having layers or changes inmaterials, densities, and/or other material properties, along the lengthof the cylinder and/or as a function of radius and/or rotationalposition with respect to the longitudinal axis of the cylindricalelement. The term tube can refer to a hollow cylindrical element thatcan have one or more features cut into or on an inner surface of thehollow passageway through the hollow cylindrical element. Other types ofcylindrical elements can also be machined in accordance with embodimentsof the subject invention, including, but not limited to, cylindricalelements having one or more partial or full bores through thecylindrical elements, and/or one or more features cut into or on anouter surface of the cylindrical element. Specific embodiments relate tomachining a single spiraling groove or multiple spiraling grooves. Forembodiments with multiple grooves, the grooves may all have the samehandedness, or may differ in handedness. Embodiments having two groovesare provided as an example to teach certain features of variousembodiments, where embodiments having a single groove to machine morethan two grooves, or alternatively, a single groove.

Specific embodiments include, but are not limited to, the following:

-   -   (i) machining one or more grooves around the outer surface of a        shaft or tube with a right hand, or clockwise, twist or with a        left hand, or counter clockwise, twist, which, in a further        specific embodiment, allows the shaft or tube to be used to        drive a carrier along the shaft or tube when the shaft or tube        is rotated.    -   (ii) machining two or more grooves around the outer surface of a        shaft or tube, where at least one groove has a right hand, or        clockwise, twist and at least one other groove has a left hand,        or counter clockwise, twist, which, in a further specific        embodiment, allows the shaft or tube to be used to drive a right        hand and/or a left hand carrier along the shaft or tube when the        shaft or tube is rotated.    -   (iii) machining one or more grooves, in accordance with (i),        including machining at least two grooves.    -   (iv) machining two or more grooves, in accordance with (ii),        including machining at least two right hand grooves and at least        two left hand grooves.    -   (v) machining one or more grooves, in accordance with (i), where        the one or more grooves are 180 degrees apart.    -   (vi) machining one or more grooves, in accordance with (i)        and/or (ii), where the one or more grooves are cut by a 0.250        inch diameter cutter at a depth of 0.040 inches.    -   (vii) machining grooves, in accordance with (i) and/or (ii),        wherein the grooves are 180 degrees apart.    -   (viii) machining grooves, in accordance with (i) and/or (ii),        using a rough cut tool to cut a rough portion of each groove and        a finish cut tool to cut a finish portion of each groove, where        the spacing of the rough cut tool and the finish cut tool is one        half the lead of the groove.

A specific embodiment of the subject invention will be described toillustrate several features that can be incorporated with variousembodiments of the invention. Referring to FIGS. 1-3, an embodiment ofan apparatus set up for cutting a pair of spiraling grooves 12 on a rodor tube 1 is shown, with the rod or tube 1 placed and secured on a lathe10. The handedness of the grooves 12 can be right handed (clockwise) orleft handed (counterclockwise). The handedness of the grooves, for acertain rotational direction of the rod or tube, can be selected by thedirectional engagement of the directional lever 7, where the directionallever controls the direction the cutting tool moves with respect to therotating cylindrical element. The traversing speed of the tool post 5 isset by one of the speed adjusters, which, for a given rotation speed andcylinder radius, will also set the traversing lead of the groove 12,where the traversing lead is the angle the groove 12 makes with respectto an axis parallel to the longitudinal axis of the cylindrical element.Lever 6 is used to engage the lead screw, which is geared to the chuckor spindle to generate the desired lead.

The groove cutting tools 11 are secured in the tool holder 9 on the toolpost 5. The rod or tube 1 is placed in the chuck 8 of the lathe 10. Avertical backup roller 4 is placed against the top surface of the rod ortube 1 and a horizontal back up roller 3 is placed against the back sideof the rod or tube 1 to support the rod while the grooves 12 are cut, asknown in the art. The tool 11 cutting depth can be set differently foreach set of tools 11, as shown in FIG. 3. While several settings can beused, in the shown embodiment the first, or rough, cutter cuts into thecylindrical element to an initial depth, which is more than half of thetotal groove depth, and the last, or finish, cutter cuts further intothe cylindrical element to deepen the groove 12. Although the roughcutter cuts into the cylindrical element more than the finish cutter inthis embodiment, in other embodiments the finish cutter can cut morethan half of the groove's depth. In an embodiment, the top of thecutter, which can be flat is perpendicular to a plane tangent to thedrive element at the point of contact between the cutter and the driveelement.

In the embodiment shown in FIG. 3, the cylindrical element is rotatingsuch that the top surface of the cylindrical element is coming out ofthe page, and the tool post 5 is moving from right to left with respectto the element 1. There are four cutters, with the first two cutters,shown on the left, making the rough depth cuts, set at a certain depth,for two separate grooves 12, and the two finish cutters, shown on theright, cutting farther into the respective groove. In the embodimentshown in FIG. 3, the rough cuts (on left in FIG. 3) are 0.030 inchesdeep, while the finish cut (on right in FIG. 3) adds an additional 0.010inches of depth to the groove for a final groove depth of 0.040 inches.

In an embodiment, the two rough cutters are spaced one-half of a leadfrom each other and the two finish cutters are spaced one-half of a leadfrom each other, such that the two grooves are spaced 180°, or one-halfof a lead, apart, where a lead is defined as the linear distance alongthe axis of the shaft or tube that is covered by one 360° rotation ofthe groove. Any number of cutters can be used to cut each groove, but toavoid two passes of the tool post 5 down the rotating element when twocutters (e.g., rough and finish) are used for each groove, two cuttersare needed for each groove. The embodiment shown in FIG. 3 produces apair of spiraling grooves as shown in FIGS. 7-8. In this embodiment, thetwo grooves are spaced 180°, or one-half of a lead, apart, but otherembodiments have spacing greater than or less than 180°.

Referring to FIGS. 4-6, the apparatus from FIGS. 1-3 is shown being usedfor cutting two opposing pairs of spiraling grooves 12 on a rod or tube,with the rod or tube 1 still in place and secured on a lathe 10 and thetool post 5 traveling in the other direction after the first pair ofgrooves were finished. FIG. 1 shows the point where a little less thanhalf the length of the first pair of grooves have been cut and the toolpost 5 is moving from right to left. The vertical backup roller 4 isagain placed against the top surface of the rod or tube 1 and ahorizontal roller 3 is placed against the back side of the rod or tube 1to support the rod while the grooves 12 having the opposite handednessof the pair of grooves shown being cut in FIG. 3 are cut, as known inthe art.

The grooves 12 of opposite handedness can be cut over (intersecting) theoriginal grooves 12 by switching the rough cutter tool holder 9 (e.g.,9R in FIGS. 2 and 3) and the finish cutter tool holder 9 (e.g., 9F inFIGS. 2 and 3) and reversing the directional lever 6 such that the toolpost 5 is moved in the opposite direction with respect to the rotatingcylindrical element as when the original grooves were cut. Thetraversing speed of the tool post 5 can remain the same as during thefirst pass and the rotation speed of the cylindrical element can remainthe same as during the first pass, such that the traversing lead staysthe same. If the same cutters are used for rough and finish cutting,rather than switching the rough cutters tool holder 9 (e.g., 9R in FIGS.2 and 3) and the finish cutters tool holder 9 (e.g., 9F in FIGS. 2 and3), the cutting depth of the groove cutting tools 11 can be changed,such that cutters set to the rough depth on the first pass (11A and 11Bin 9R in FIG. 3) are set to the finish depth on the second pass (11A and11B in 9F in FIG. 6) and the cutters set to the finish depth on thefirst pass (11A and 11B in 9F in FIG. 3) are set to the rough depth onthe second pass (11A and 11B in 9R in FIG. 6), and secured in the toolholder 9 on the tool post 5. In the embodiment shown in FIGS. 7-8, thereare four cutters with the first two cutters making a rough depth cut setat a rough depth and the finish cutters cutting farther into the grooveto the final depth. In the embodiment shown in FIGS. 7-8, the rough cutis 0.030 inches deep while the finish cut cuts an additional 0.010inches resulting in a depth of 0.04 inches for the groove.

Again, the two rough cutters are spaced one-half a lead from each otherand the two finish cutters are spaced one-half of a lead from eachother. As before, any number of cutters can be used, but to avoidneeding two passes of the tool post 5 down the rotating element when twotools are used for each groove, two rough cutters and two finish cuttersare needed. For embodiments having two right hand grooves and two lefthand grooves, and using a rough cutter and a finish cutter for eachgroove, four cutters are needed to accomplish the four grooves in twopasses. This produces two opposing pairs of spiraling grooves as shownin FIGS. 9-10. In this embodiment, the grooves are spaced 180° apart, asmeasured around the perimeter of the rod, but other embodiments havingspacing greater than or less than 180° are contemplated.

In regard to the tolerance of the groove “pitch” spacing, embodiments ofthe subject tool holder ensure such spacing is consistent. In anembodiment, a 4.0″ lead works well in relation to speeds and feedcapability of the curtain, but other leads are also utilized. Anembodiment has a tolerance of +/−0.12″ on the pitch, which is based onthe feed speed of the machine (lathe) cutting the grooves and should bevery consistent.

The groove radius can be based on a 0.125 Radius tool, by using amachining center to cut the groove and a ¼″ ball end mill. Inembodiments using a lathe, different cutters are used. The actualfinished shape of the groove is approximately a true radius at 0.118″.Different tools can be used for each cut on the tube such that thefinished groove is 0.118 Radius.

In an embodiment using a lathe, the tolerances for the groove depth are+/−0.010″.

FIG. 11A shows a perspective view of a stock bit, or tool, 11 used tocut a portion of an outer surface or a tube or shaft to create a groovein the outer surface of the tube or shaft, where the angle θ that thebit's front portion ball 13, which faces the outer surface of the tubeor shaft, make with respect to a line 14 perpendicular to the topsurface 15 at the bit 11. The angle θ for a specific stock bit 11 isapproximately 11°. FIG. 11B shows an embodiment of bit 11 that can beutilized to cut a portion of a groove 12 in accordance with anembodiment of the subject invention, which has an θ>30°. The increaseangle allows the bit to cut a portion of a groove that has a lead anglethat might cause the standard bit to rub the side of the groove duringcutting, particularly for the bit 11 cutting a finish portion, ordeepest portion, of the groove. FIG. 11C shows an embodiment of a bit 11in accordance with the subject invention having an angle θ of 45°.Specific embodiments of the invention can utilize bits 11 having anangle θ>15°, θ>20°, θ>25°, θ>30°, θ>35°, θ>40°, θ>45°, 15°>θ>20°,20°>θ>25°, 25°>θ>30°, 30°>θ>35°, 35°>θ>40°, and/or 40°>θ>45°. The bitcan be produced by, for example, grinding away a portion of a standardbit having an angle θ=11°. Various embodiments can utilize rough cutterbits and finish cutter bits that are the same or different, two cutterbits for two grooves that are the same or different, in shape, size,material, or other properties.

FIGS. 12A, 12B, and 12C show an embodiment of a tool holder 9 thatincorporates two rows of tools 11, a top row that has tools 11 forcutting grooves in a tube or shaft where the tool holder 9 is movedright to left with respect to the rotating tube or shaft, and a bottomrow that has tools 11 for cutting grooves in a tube or shaft where thetool holder 9 is moved left to right with respect to the rotating tubeor shaft, where for both the top row and bottom row, rough cutters startcutting the grooves and finish cutters finish the grooves. Theembodiment shown in FIGS. 12A-12C incorporates 5 pairs of cutters whereeach pair, having a left cutter and a right cutter, cuts further thanthe adjacent pair, and the five left cutters of the five pairs cuts afirst groove and the five right cutters of the five pairs cuts a secondgroove, and the top row cuts a pair of grooves of a first handedness andthe bottom row cuts a pair of grooves of the opposite handedness.

Embodiments of the invention are directed to a method and apparatus forcutting one or more grooves into an outer surface of a cylindricalelement. A specific embodiment, which can be referred to as Embodiment1, involves:

rotating a cylindrical element about a longitudinal axis of thecylindrical element;

where, while rotating the cylindrical element about the longitudinalaxis, further incorporating:

moving a rough cutter and the rotating cylindrical element with respectto each other in a direction parallel to the longitudinal axis, wherethe rough cutter moves from a rough start position to a rough endposition, wherein the rough start position has a rough axial startposition along a length of the cylindrical element and a roughrotational start position about the longitudinal axis, where the roughend position has a rough axial end position along a length of thecylindrical element and a rough rotational end position about thelongitudinal axis; and

moving a finish cutter and the rotating cylindrical element with respectto each other in a direction parallel to the longitudinal axis, whereinthe finish cutter moves from a finish start position to a finish endposition, where the finish start position has a finish axial startposition along the length of the cylindrical element and a finishrotational start position about the longitudinal axis, where the finishend position has a finish axial end position along a length of thecylindrical element and a finish rotational end position about thelongitudinal axis;

where, while moving the rough cutter from the rough start position tothe third position, positioning the rough cutter with respect to anouter surface of the cylindrical element such that the rough cutter cutsaway a rough portion of the outer surface,

where, while moving the finish cutter from the finish start position tothe finish end position, positioning the finish cutter with respect tothe outer surface of the cylindrical element such that the finish cuttercuts away a finish portion of the outer surface,

where, cutting away the rough portion and cutting away the finishportion creates a groove in the outer surface of the cylindricalelement.

Moving the cutters and the rotating element can be accomplished byrotating the element in place and moving the cutters along the outersurface of the rotating element, holding the cutters in place and movingthe rotating element, or moving both the cutters and the rotatingelement. The rough cutter and finish cutter can be started at the samerotational positions or at different rotational positions, theserotational positions can remain the same as the cutters and rotatingelement are moved relative to each other, or can vary, and the speed ofsuch relative movement can vary or be constant. The rotating element canbe rotated at a constant rotational speed or the rotational speed canvary while the rotating element and cutters move with respect to eachother. The cutters can remain in constant contact with the outer surfaceof the rotating element or can be disengaged from contact with the outersurface, the cutters can cut to a constant depth when engaged with theouter surface or the depth can vary while engaged with the outersurface, the rough cutter and the finish cutter can move at the samespeed or different speed and such speeds can be constant or vary.Likewise, embodiments using two rough cutters and/or two finish cutterscan have the rough cutters and/or the finish cutters move at the samespeed or different speeds, during the relative motion of the rotatingelement and the cutters. Two passes can be made in the same direction orin opposite directions, as desired. The cylinder can be rotated ineither direction, with an appropriate position of the cutters.

In specific embodiments, incorporating the limitations of Embodiment 1,when the finish rotational start position is the same as the roughrotational start position, the finish axial start position is axiallyseparated from the rough axial start position by n leads, where a leadis an axial distance covered by one 360° rotation of the groove in theouter surface of the cylindrical element and n is an integer having avalue of 1 or greater. This allows the finish cutter to cut further intothe groove started by the rough cutter. In a specific embodiment, n=1,and the axial start positions are separated by one lead.

In a specific embodiment, which can be referred to as the secondembodiment, wherein the rough rotational end position is the same as therough rotational start position, wherein the finish rotational endposition is the same as the finish rotational start position, whereinthe finish rotational start position is the same as the rough rotationalstart position, where while moving the rough cutter from the rough startposition to the rough end position, the rough cutter is maintained atthe rough rotational start position, where while moving the finishcutter from the finish start position to the finish end position, thefinish cutter is maintained at the finish rotational start position,where rotating the cylindrical element comprises rotating thecylindrical element at a constant speed of rotation, where moving therough cutter from the rough start position to the rough end positioncomprises moving the rough cutter from the rough start position to therough end position at a first axial speed, wherein the first axial speedis a constant axial speed, where moving the finish cutter from thefinish start position to the finish end position comprises moving thefinish cutter from the finish start position to the finish end positionat the first axial speed, where the finish axial start position isaxially separated from the rough axial start position by n leads, wherea lead is an axial distance covered by one 360° rotation of the groovein the outer surface of the cylindrical element and n is an integerhaving a value of 1 or greater, where n=1.

In a further embodiment, which can be referred to as the thirdembodiment, incorporating the limitations of Embodiment 1, whilerotating the cylindrical element about the longitudinal axis, furtherincluding:

moving a second rough cutter and the rotating cylindrical element withrespect to each other in the direction parallel to the longitudinalaxis, wherein the second rough cutter moves from a second rough startposition to a second rough end position, where the second rough startposition has a second rough axial start position along the length of thecylindrical element and a second rough rotational start position aboutthe longitudinal axis, where the second rough end position has a secondrough axial end position along the length of the cylindrical element anda second rough rotational end position about the longitudinal axis; and

moving a second finish cutter and the rotating cylindrical element withrespect to each other in a direction parallel to the longitudinal axis,wherein the second finish cutter moves from a second finish startposition to a second finish end position, where the second finish startposition has a second finish axial start position along the length ofthe cylindrical element and a second finish rotational start positionabout the longitudinal axis, where the second finish end position has asecond finish axial end position along the length of the cylindricalelement and a second finish rotational end position about thelongitudinal axis;

where while moving the second rough cutter from the second rough startposition to the second rough end position, positioning the second roughcutter with respect to the outer surface of the cylindrical element suchthat the second rough cutter cuts away a second rough portion of theouter surface,

where while moving the second finish cutter from the second finish startposition to the second finish end position, positioning the secondfinish cutter with respect to the outer surface of the cylindricalelement such that the second finish cutter cuts away a second finishportion of the outer surface,

where cutting away the second rough portion and cutting away the secondfinish portion creates a second groove in the outer surface of thecylindrical element.

In a further specific embodiment, which can be referred to as the fourthembodiment, incorporating the limitations of Embodiment three, thesecond finish axial start position is axially separated from the secondrough axial start position by m leads, where m is an integer having avalue of 1 or greater. In this way the second finish cutter follows inthe groove started by the second rough cutter. In a specific embodiment,m=1.

In a further specific embodiment, which can be referred to as embodimentfive, incorporating the limitations of Embodiment four, where the secondrough axial start position is axially separated from the finish axialstart position by (p+½) leads, where p is an integer having a value ofzero or greater, where p=0.

In a further specific embodiment, which can be referred to as Embodimentsix, incorporating the limitations of Embodiment 1, while rotating thecylindrical element about the longitudinal axis, further incorporating:

moving a second rough cutter and the rotating cylindrical element withrespect to each other in the direction parallel to the longitudinalaxis, where the second rough cutter moves from a second rough startposition to a second rough end position, where second rough startposition has a second rough axial start position along the length of thecylindrical element and a second rough rotational start position aboutthe longitudinal axis, where second rough end position has a secondrough axial end position and a second rough rotational end position; and

moving the second finish cutter and the rotating cylindrical elementwith respect to each other in the direction parallel to the longitudinalaxis, where the second finish cutter moves from a second finish startposition to an second finish end position, where the second finish startposition has a second finish axial start position along the length ofthe cylindrical element and a second finish rotational start positionabout the longitudinal axis, where the second finish end position has asecond finish axial end position and a second finish rotational endposition;

where while moving the second rough cutter from the second rough startposition to the second rough end position, positioning the second roughcutter with respect to the outer surface of the cylindrical element suchthat the second rough cutter cuts away a second rough portion of theouter surface,

where while moving the second finish cutter from the second finish startposition to the second finish end position, positioning the secondfinish cutter with respect to the outer surface of the cylindricalelement such that the second finish cutter cuts away a second finishportion of the outer surface,

where cutting away the second rough portion and cutting away the secondfinish portion creates a second groove in the outer surface of thecylindrical element.

A specific embodiment, which can be referred to as Embodiment seven,relates to a method and apparatus for cutting two grooves into an outersurface of a cylindrical element, involving:

rotating the cylindrical element about the longitudinal axis of acylindrical element;

moving a first cutter and the rotating cylindrical element with respectto each other in the direction parallel to the longitudinal axis, wherethe first cutter moves from a first start position to a first endposition, where the first start position has a first axial startposition along a length of the cylindrical element and a firstrotational start position about the longitudinal axis, where the firstend position has a first axial end position along a length of thecylindrical element and a first rotational end position about thelongitudinal axis; and

moving a second cutter and the rotating cylindrical element with respectto each other in the direction parallel to the longitudinal axis, wherethe second cutter moves from a second start position to a second endposition, where the second start position has a second axial startposition along the length of the cylindrical element and a secondrotational start position about the longitudinal axis, where the secondend position has a second axial end position along a length of thecylindrical element and a second rotational end position about thelongitudinal axis;

where while moving the first cutter from the first start position to thefirst end position, positioning the first cutter with respect to anouter surface of the cylindrical element such that the first cutter cutsaway a first portion of the outer surface,

where while moving the second cutter from the second start position tothe second end position, positioning the second cutter with respect tothe outer surface of the cylindrical element such that the second cuttercuts away a second portion of the outer surface,

where cutting away the first portion creates a first groove in the outersurface of the cylindrical element, and

where cutting away the second portion creates a second groove in theouter surface of the cylindrical element.

In a further specific embodiment, which can be referred to as Embodimenteight, incorporating the limitations of Embodiment seven, the firstrotational end position is the same as the first rotational startposition, the second rotational end position is the same as the secondrotational start position, the second rotational start position is thesame as the first rotational start position, where while moving thefirst cutter from the first start position to the first end position,the first cutter is maintained at the first rotational start position,where while moving the second cutter from the second start position tothe second end position, the second cutter is maintained at the secondrotational start position, where the second rotational start position isthe same as the first rotational start position, where rotating thecylindrical element comprises rotating the cylindrical element at aconstant speed of rotation, where moving the first cutter from the firststart position to the first end position comprises moving the firstcutter from the first start position to the first end position at afirst axial speed, where the first axial speed is a constant axialspeed, wherein moving the second cutter from the second start positionto the second end position comprises moving the second cutter from thesecond start position to the second end position at the first axialspeed, where the second axial start position is axially separated fromthe first axial start position by a separation axial distance, where thesecond groove is separated from the first groove by the separation axialdistance, where the separation axial distance is (k+½) leads, where alead is an axial distance covered by one 360° rotation of the firstgroove in the outer surface of the cylindrical element and k is aninteger having a value of zero or greater, where k=0.

Aspects of the invention, such as controlling the transverse, andproximity to the rotating cylindrical element, of the tool box 5, andthe rotation of the cylindrical element, may be described in the generalcontext of computer-executable instructions, such as program modules,being executed by a computer. Generally, program modules includeroutines, programs, objects, components, data structures, etc., thatperform particular tasks or implement particular abstract data types.Moreover, those skilled in the art will appreciate that the inventionmay be practiced with a variety of computer-system configurations,including multiprocessor systems, microprocessor-based orprogrammable-consumer electronics, minicomputers, mainframe computers,and the like. Any number of computer-systems and computer networks areacceptable for use with the present invention.

Specific hardware devices, programming languages, components, processes,protocols, and numerous details including operating environments and thelike are set forth to provide a thorough understanding of the presentinvention. In other instances, structures, devices, and processes areshown in block-diagram form, rather than in detail, to avoid obscuringthe present invention. But an ordinary-skilled artisan would understandthat the present invention may be practiced without these specificdetails. Computer systems, servers, work stations, and other machinesmay be connected to one another across a communication medium including,for example, a network or networks.

As one skilled in the art will appreciate, embodiments of the presentinvention may be embodied as, among other things: a method, system, orcomputer-program product. Accordingly, the embodiments may take the formof a hardware embodiment, a software embodiment, or an embodimentcombining software and hardware. In an embodiment, the present inventiontakes the form of a computer-program product that includescomputer-useable instructions embodied on one or more computer-readablemedia.

Computer-readable media include both volatile and nonvolatile media,transitory and non-transitory, removable and nonremovable media, andcontemplate media readable by a database, a switch, and various othernetwork devices. By way of example, and not limitation,computer-readable media comprise media implemented in any method ortechnology for storing information. Examples of stored informationinclude computer-useable instructions, data structures, program modules,and other data representations. Media examples include, but are notlimited to, information-delivery media, RAM, ROM, EEPROM, flash memoryor other memory technology, CD-ROM, digital versatile discs (DVD),holographic media or other optical disc storage, magnetic cassettes,magnetic tape, magnetic disk storage, and other magnetic storagedevices. These technologies can store data momentarily, temporarily, orpermanently.

The invention may be practiced in distributed-computing environmentswhere tasks are performed by remote-processing devices that are linkedthrough a communications network. In a distributed-computingenvironment, program modules may be located in both local and remotecomputer-storage media including memory storage devices. Thecomputer-useable instructions form an interface to allow a computer toreact according to a source of input. The instructions cooperate withother code segments to initiate a variety of tasks in response to datareceived in conjunction with the source of the received data.

The present invention may be practiced in a network environment such asa communications network. Such networks are widely used to connectvarious types of network elements, such as routers, servers, gateways,and so forth. Further, the invention may be practiced in a multi-networkenvironment having various, connected public and/or private networks.

Communication between network elements may be wireless or wireline(wired). As will be appreciated by those skilled in the art,communication networks may take several different forms and may useseveral different communication protocols. And the present invention isnot limited by the forms and communication protocols described herein.

All patents, patent applications, provisional applications, andpublications referred to or cited herein are incorporated by referencein their entirety, including all figures and tables, to the extent theyare not inconsistent with the explicit teachings of this specification.

It should be understood that the examples and embodiments describedherein are for illustrative purposes only and that various modificationsor changes in light thereof will be suggested to persons skilled in theart and are to be included within the spirit and purview of thisapplication.

REFERENCE NUMBERS

-   -   1. Cylindrical element (rod or tube)    -   2. Backup rollers holder    -   3. Horizontal backup roller    -   4. Vertical backup roller    -   5. Tool post    -   6. Lever to engage lead screw    -   7. Directional lever    -   8. Chuck, part holder    -   9. Tool holder    -   10. Lathe    -   11. Tool    -   12. Groove    -   13. Bit front portion    -   14. Line    -   15. Bit top surface

I claim:
 1. A method of cutting one or more grooves into an outersurface of a cylindrical element, comprising: rotating a cylindricalelement about a longitudinal axis of the cylindrical element; whereinwhile rotating the cylindrical element about the longitudinal axis,further comprising: moving a rough cutter and the rotating cylindricalelement with respect to each other in a direction parallel to thelongitudinal axis, wherein the rough cutter moves from a rough startposition to a rough end position, wherein the rough start position has arough axial start position along a length of the cylindrical element anda rough rotational start position about the longitudinal axis, whereinthe rough end position has a rough axial end position along a length ofthe cylindrical element and a rough rotational end position about thelongitudinal axis; and moving a finish cutter and the rotatingcylindrical element with respect to each other in a direction parallelto the longitudinal axis, wherein the finish cutter moves from a finishstart position to a finish end position, wherein the finish startposition has a finish axial start position along the length of thecylindrical element and a finish rotational start position about thelongitudinal axis, wherein the finish end position has a finish axialend position along a length of the cylindrical element and a finishrotational end position about the longitudinal axis; wherein whilemoving the rough cutter from the rough start position to the thirdposition, positioning the rough cutter with respect to an outer surfaceof the cylindrical element such that the rough cutter cuts away a roughportion of the outer surface, wherein while moving the finish cutterfrom the finish start position to the finish end position, positioningthe finish cutter with respect to the outer surface of the cylindricalelement such that the finish cutter cuts away a finish portion of theouter surface, wherein cutting away the rough portion and cutting awaythe finish portion creates a groove in the outer surface of thecylindrical element.
 2. The method according to claim 1, wherein therough rotational end position is the same as the rough rotational startposition.
 3. The method according to claim 2, wherein the finishrotational end position is the same as the finish rotational startposition.
 4. The method according to claim 3, wherein the finishrotational start position is the same as the rough rotational startposition.
 5. The method according to claim 2, wherein while moving therough cutter from the rough start position to the rough end position,the rough cutter is maintained at the rough rotational start position.6. The method according to claim 3, wherein while moving the finishcutter from the finish start position to the finish end position, thefinish cutter is maintained at the finish rotational start position. 7.The method according to claim 4, wherein while moving the rough cutterfrom the rough start position to the rough end position, the roughcutter is maintained at the rough rotational start position, whereinwhile moving the finish cutter from the finish start position to thefinish end position, the finish cutter is maintained at the finishrotational start position.
 8. The method according to claim 1, whereinrotating the cylindrical element comprises rotating the cylindricalelement at a constant speed of rotation.
 9. The method according toclaim 7, wherein rotating the cylindrical element comprises rotating thecylindrical element at a constant speed of rotation.
 10. The methodaccording to claim 9, wherein moving the rough cutter from the roughstart position to the rough end position comprises moving the roughcutter from the rough start position to the rough end position at afirst axial speed, wherein the first axial speed is a constant axialspeed, wherein moving the finish cutter from the finish start positionto the finish end position comprises moving the finish cutter from thefinish start position to the finish end position at the first axialspeed.
 11. The method according to claim 10, wherein the finish axialstart position is axially separated from the rough axial start positionby n leads, where a lead is an axial distance covered by one 360°rotation of the groove in the outer surface of the cylindrical elementand n is an integer having a value of 1 or greater.
 12. The methodaccording to claim 11, wherein n=1.
 13. The method according to claim12, wherein while rotating the cylindrical element about thelongitudinal axis, further comprising: moving a second rough cutter andthe rotating cylindrical element with respect to each other in thedirection parallel to the longitudinal axis, wherein the second roughcutter moves from a second rough start position to a second rough endposition, wherein the second rough start position has a second roughaxial start position along the length of the cylindrical element and asecond rough rotational start position about the longitudinal axis,wherein the second rough end position has a second rough axial endposition along the length of the cylindrical element and a second roughrotational end position about the longitudinal axis; and moving a secondfinish cutter and the rotating cylindrical element with respect to eachother in a direction parallel to the longitudinal axis, wherein thesecond finish cutter moves from a second finish start position to asecond finish end position, wherein the second finish start position hasa second finish axial start position along the length of the cylindricalelement and a second finish rotational start position about thelongitudinal axis, wherein the second finish end position has a secondfinish axial end position along the length of the cylindrical elementand a second finish rotational end position about the longitudinal axis;wherein while moving the second rough cutter from the second rough startposition to the second rough end position, positioning the second roughcutter with respect to the outer surface of the cylindrical element suchthat the second rough cutter cuts away a second rough portion of theouter surface, wherein while moving the second finish cutter from thesecond finish start position to the second finish end position,positioning the second finish cutter with respect to the outer surfaceof the cylindrical element such that the second finish cutter cuts awaya second finish portion of the outer surface, wherein cutting away thesecond rough portion and cutting away the second finish portion createsa second groove in the outer surface of the cylindrical element.
 14. Themethod according to claim 13, wherein the second rough rotational startposition, the second finish rotational start position, the second roughrotational end position, and the second finish rotational end positionare the same as the rough rotational start position.
 15. The methodaccording to claim 14, wherein while moving the second rough cutter fromthe second rough start position to the second rough end position, thesecond rough cutter is maintained at the second rough rotational startposition wherein while moving the second finish cutter from the secondfinish start position to the second finish end position, the secondfinish cutter is maintained at the second finish rotational startposition.
 16. The method according to claim 15, wherein moving thesecond rough cutter from the second rough start position to the secondrough end position comprises moving the second rough cutter from thesecond rough start position to the second rough end position at thefirst axial speed, wherein moving the second finish cutter from thesecond finish start position to the second finish end position comprisesmoving the second finish cutter from the second finish start position tothe second finish end position at the first axial speed.
 17. The methodaccording to claim 16, wherein the second finish axial start position isaxially separated from the second rough axial start position by m leads,where m is an integer having a value of 1 or greater.
 18. The methodaccording to claim 17, wherein m=1.
 19. The method according to claim18, wherein the second rough axial start position is axially separatedfrom the finish axial start position by (p+½) leads, wherein p is aninteger having a value of zero or greater.
 20. The method according toclaim 19, wherein p=0.
 21. The method according to claim 1, whereinwhile rotating the cylindrical element about the longitudinal axis,further comprising: moving a second rough cutter and the rotatingcylindrical element with respect to each other in the direction parallelto the longitudinal axis, wherein the second rough cutter moves from asecond rough start position to a second rough end position, whereinsecond rough start position has a second rough axial start positionalong the length of the cylindrical element and a second roughrotational start position about the longitudinal axis, wherein secondrough end position has a second rough axial end position and a secondrough rotational end position; and moving the second finish cutter andthe rotating cylindrical element with respect to each other in thedirection parallel to the longitudinal axis, wherein the second finishcutter moves from a second finish start position to an second finish endposition, wherein the second finish start position has a second finishaxial start position along the length of the cylindrical element and asecond finish rotational start position about the longitudinal axis,wherein the second finish end position has a second finish axial endposition and a second finish rotational end position; wherein whilemoving the second rough cutter from the second rough start position tothe second rough end position, positioning the second rough cutter withrespect to the outer surface of the cylindrical element such that thesecond rough cutter cuts away a second rough portion of the outersurface, wherein while moving the second finish cutter from the secondfinish start position to the second finish end position, positioning thesecond finish cutter with respect to the outer surface of thecylindrical element such that the second finish cutter cuts away asecond finish portion of the outer surface, wherein cutting away thesecond rough portion and cutting away the second finish portion createsa second groove in the outer surface of the cylindrical element.
 22. Amethod of cutting two grooves into an outer surface of a cylindricalelement, comprising: rotating the cylindrical element about thelongitudinal axis of a cylindrical element; moving a first cutter andthe rotating cylindrical element with respect to each other in thedirection parallel to the longitudinal axis, wherein the first cuttermoves from a first start position to a first end position, wherein thefirst start position has a first axial start position along a length ofthe cylindrical element and a first rotational start position about thelongitudinal axis, wherein the first end position has a first axial endposition along a length of the cylindrical element and a firstrotational end position about the longitudinal axis; and moving a secondcutter and the rotating cylindrical element with respect to each otherin the direction parallel to the longitudinal axis, wherein the secondcutter moves from a second start position to a second end position,wherein the second start position has a second axial start positionalong the length of the cylindrical element and a second rotationalstart position about the longitudinal axis, wherein the second endposition has a second axial end position along a length of thecylindrical element and a second rotational end position about thelongitudinal axis; wherein while moving the first cutter from the firststart position to the first end position, positioning the first cutterwith respect to an outer surface of the cylindrical element such thatthe first cutter cuts away a first portion of the outer surface, whereinwhile moving the second cutter from the second start position to thesecond end position, positioning the second cutter with respect to theouter surface of the cylindrical element such that the second cuttercuts away a second portion of the outer surface, wherein cutting awaythe first portion creates a first groove in the outer surface of thecylindrical element, and wherein cutting away the second portion createsa second groove in the outer surface of the cylindrical element.
 23. Themethod according to claim 22, wherein the first rotational end positionis the same as the first rotational start position.
 24. The methodaccording to claim 23, wherein the second rotational end position is thesame as the second rotational start position.
 25. The method accordingto claim 24, wherein the second rotational start position is the same asthe first rotational start position.
 26. The method according to claim22, wherein while moving the first cutter from the first start positionto the first end position, the first cutter is maintained at the firstrotational start position.
 27. The method according to claim 24, whereinwhile moving the second cutter from the second start position to thesecond end position, the second cutter is maintained at the secondrotational start position.
 28. The method according to claim 25, whereinwhile moving the first cutter from the first start position to the firstend position, the first cutter is maintained at the first rotationalstart position, wherein while moving the second cutter from the secondstart position to the second end position, the second cutter ismaintained at the second rotational start position.
 29. The methodaccording to claim 28, wherein the second rotational start position isthe same as the first rotational start position.
 30. The methodaccording to claim 22, wherein rotating the cylindrical elementcomprises rotating the cylindrical element at a constant speed ofrotation.
 31. The method according to claim 29, wherein rotating thecylindrical element comprises rotating the cylindrical element at aconstant speed of rotation.
 32. The method according to claim 31,wherein moving the first cutter from the first start position to thefirst end position comprises moving the first cutter from the firststart position to the first end position at a first axial speed, whereinthe first axial speed is a constant axial speed, wherein moving thesecond cutter from the second start position to the second end positioncomprises moving the second cutter from the second start position to thesecond end position at the first axial speed.
 33. The method accordingto claim 32, wherein the second axial start position is axiallyseparated from the first axial start position by a separation axialdistance, wherein the second groove is separated from the first grooveby the separation axial distance.
 34. The method according to claim 33,wherein the separation axial distance is (k+½) leads, where a lead is anaxial distance covered by one 360° rotation of the first groove in theouter surface of the cylindrical element and k is an integer having avalue of zero or greater.
 35. The method according to claim 34, whereink=0.